Sustainability Analysis of Grinding with Power Tools

Laboratory For Manufacturing and Sustainability, 2011

Production engineering is under constant pressure to satisfy demands for improved productivity while simultaneously achieving high workpiece quality. In addition, environmental awareness is a growing concern to address. New technologies represent new opportunities for increased productivity. This paper shows how the combination of speed stroke grinding and high speed machining can boost both process performance and workpiece quality. Theoretical consideration is validated by experiments and analyzed regarding energetic and environmental aspects. Only a thorough choice of process parameters leads to high process sustainability. Furthermore, lower tensile stresses can positively leverage increased manufacturing effort to optimize the overall product life cycle.

Procedia CIRP, 2016

Current machining practice in a SouthEast England SME was studied over a 6 month period. This was preceded by exploratory academic research in sustainable machining and a set of short industrial observations/interviews. Preliminary machining tests conducted in the industry on Delrin, aluminium, carbon steel, stainless steel and Inconel 718 indicated more energy savings would be desirable with Inconel. New cutting tools were developed with potential to reduce energy consumption and tested on various features. The effect of using a trochoidal toolpath was also investigated. The results show that energy reduction was obtained for some of the features. Surface finish and tool wear and quality of type of chip produced were not impaired. The results have raised awareness of the potential for energy reduction in the SME and a major tool manufacturer involved in the study. The study has acted as exploration of factors important in the dissemination of sustainable machining in industry.

Procedia Manufacturing, 2020

Manufacturing industry largely contributes towards the economy of a country. However, it leaves a significant environmental footprint mainly caused by process energy. With the emphasis on sustainable means of manufacturing, this study focuses on the sustainability of milling. An industrial milling operation is monitored to collect the energy consumption data using an energy data logger. SimaPro® LCA software is used with ISO 14044 guidelines to quantify the environmental impact associated with the milling unit processes. The results show that different parameter combinations significantly affect the total environmental impact. It concludes by suggesting favourable parameter combinations leading to better environmental performance.

2017

Machining plays an vital role in industrial economy and it contributes. more than 5% to the country’s economy. The machining processes has gone through significant changes in the last decades. Competition has increased drastically to gain more profit. Machining processes are been used widely and attempts have been made to minimize the machining cost and the energy consumption. To achieve sustainability the machining parameters like speed, feed , depth of cut and the coolants used play an important role. Our main focus in this work is to increase the surface integrity and the tool life by making use of minimum resources and attain sustainability in machining to reduce the energy consumption.

Springer eBooks, 2021

The International Journal of Advanced Manufacturing Technology, 2018

Due to the rising concerns related to the depletion of fossil fuel sources, and the climate change associated to the usage of such sources for electricity generation, there is a high pressure for diminishing the energy consumption of all the industrial sectors in order to mitigate the negative impacts associated to the energy required to manufacture a product. Computer numerical control (CNC) machining accounts for a larger portion of the total energy drawn from the grid by the manufacturing sector. Therefore, the energy efficiency of the manufacturing operations should be enhanced to optimize their energy consumption and to reduce their environmental burden as well. As a mean for achieving sustainable manufacturing operations, the present paper outlines an experimental study to optimize cutting parameters in turning of AISI 1045 steel. One of the main objectives was to minimize the total specific energy consumed by the CNC machine tool during material removal, considering dry cutting to decrease the environmental impacts linked to the coolant usage. As a measure of the surface quality, the second objective was to reduce the average surface roughness of the workpiece. The same material removal volume was considered for all the experimental trials. The response surface method was used to obtain the regression models for all the variables studied, and the desirability method was selected for defining the values of these variables, named the cutting parameters, that minimized the quantity of electrical energy consumed, and surface roughness. The results achieved showed that it is possible to obtain a more sustainable machining process without sacrificing the productivity of the process and the final quality of the product.

Science of The Total Environment, 2020

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2019

The energy efficiency of grinding depends on the appropriate selection of cutting conditions, grinding wheel and workpiece material. Additionally, the estimation of specific energy consumption is a good indicator to control the energy consumed during the grinding process. Consequently, this study develops a model of material removal rate to estimate the specific energy consumption based on the measurement of active power consumed in a plane surface grinding of C45K with different thermal treatments and AISI 304. This model identifies and evaluates the power dissipated by sliding, ploughing and chip formation in a industrial-scale grinding process. Furthermore, the instantaneous positions of the abrasive grains during cutting are described to study the material removal rate. The estimation of specific chip formation energy is similar to that described by other authors in laboratory scale, which allows to validate the model and experiments. Finally, the results show that the energy co...

Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2019

Metal-cutting process deals with the removal of material using the shearing operation with the help of hard cutting tools. Machining operations are famous in the manufacturing sector due to their capability to manufacture tight tolerances and high dimensional accuracy while simultaneously maintaining the cost-effectiveness for higher production levels. As metal-cutting processes consume a great amount of input resources and generate some material-based waste streams, these processes are highly criticized due to their high and negative environmental impacts. Researchers in the metal-cutting sector are currently exploring and benchmarking different activities and best practices to make the cutting operation environment friendly in nature. These eco-friendly practices mainly cover the wide range of activities directly or indirectly associated with the metal-cutting operation. Most of the literature for sustainable metal-cutting activities revolves around the sustainable lubrication tec...

Journal of Cleaner Production, 2015

In the 1990s, the industrial application of high-speed machining achieved enormous success because of its favorable characteristics such as high productivity, better work quality, and ease of machining thin-walled structures. With fast changing emphasis of the world's manufacturing sector towards environmental benignity, the issue of sustainability with regard to application of high-speed machining becomes pivotal. The article presents an experimental investigation regarding comparison of conventional machining and high-speed machining with respect to sustainability measures. A set of 64 grooving experiments was performed on two tempers each of a high-strength low-alloy steel and a heat treatable titanium alloy. The experimental design focused on studying the effects of cutting mode (conventional/ high-speed machining), cutting speed levels for each of the two modes, feed rate, and minimum quantity lubrication on tool life, specific cutting energy, productivity, process cost, and machining forces. It was found that the choice between the two machining modes is highly sensitive with respect to manufacturing sustainability. The conventional machining mode was found to be comparatively economical, while the high-speed machining mode significantly outperformed the other in terms of low specific energy consumption and high productivity. The article asserts that high speed machining can completely surpass conventional machining as the sustainable way of metal cutting if the ways could be found to curb excessive tool damage observable at high cutting speeds.